Method of producing multi-panel mailing envelope forms in side-by-side interconnected series

ABSTRACT

The methods of the present invention provide for the manufacture of a series of side-by-side interconnected, single-ply, multipanel envelope forms from a continuously advancing web of sheet material. The forms are adapted to be continuously fan-folded into sealed, envelope-defining relationship, and to be thereafter severed from the series as individual items for distribution. A stuffer-insert, such as a circular or the like, may be inserted in the interior of the envelope prior to sealing thereof.

Unlted States Patent 1 11 3,902,655 Huffman Sept. 2, 1975 [54] METHOD OFPRODUCING MULTI-PANEL 3,428,237 2/1969 Dowen 229/69 M I NG ENVELOPEFORMS IN 3,482,780 12/1969 .lohnsen 229/69 3,790,070 2/1974 Schnitzer etal. 229/69 SHHLBY-SIDE INTERCONNECTED SERIES 3,837,565 9/1974 Johnsen229/85 X Harold W. Huffman, 2100 John Gray Rd., Fairfield, Ohio 45014Filed: May 13, 1974 Appl. No.: 469,673

Inventor:

US. Cl. 229/69; 229/85; 229/92.1;

229/92.7 Int. Cl. B65D 27/10 Field of Search 229/69, 85, 92.1, 92.3,229/92.7

References Cited UNITED STATES PATENTS Primary Examiner-William 1. PriceAssistant ExaminerStephen P. Garbe Attorney, Agent, or Firm-J. WarrenKinney, Jr.

[5 7] ABSTRACT The methods of the present invention provide for themanufacture of a series of side-by-side interconnected, single-ply,multi-panel envelope forms from a continuously advancing web of sheetmaterial. The forms are adapted to be continuously fan-folded intosealed, envelope-defining relationship, and to be thereafter severedfrom the series as individual items for distribution A stuffer-insert,such as a circular or the like, may be inserted in the interior of theenvelope prior to sealing thereof. 1

4 Claims, 28 Drawing Figures PATENTED SEP 2 75 SHEET PATENTEDSEP 2|9753,902,655

sum Q a 5;

METHOD OF PRODUCING MULTI-PANEL MAILING ENVELOPE FORMS IN SIDE-BY-SIDEINTERCONNECTED SERIES CROSS-REFERENCE TO RELATED APPLICATION The presentapplication is related to my copending application entitled: MULTl-PANELENVELOPE FORM AND METHOD OF PRODUCING SAME, Ser. No. 469,672, filed oneven date herewith, in which 1 have disclosed a single-ply, multi-panelenvelope form and the methods of producing an end-to-end interconnectedseries of said forms from an endless web of sheet material. The envelopeforms therein disclosed are produced from a continuously advancing webof sheet material which is transversely subdivided into a plurality ofcnd-to-end interconnected forms, each of which comprises a pair ofend-adjacent, coplanar, envelopedefining panels separated by at leastone endconnected, intermediate panel. The end-to-end interconnectedforms are each adapted to be sequentially zig-zag folded into sealed,envelope-defining relationship.

The methods disclosed in the present application are readilydistinguishable therefrom, wherein a continuously advancing, endless webof sheet material is transversely subdivided into a plurality ofside-by-side interconnected forms which are adapted to be continuouslyfan-folded into sealed, envelope-defining relationship. The presentapplication is specifically limited and dirccted to the methodsdisclosed herein.

BACKGROUND OF THE INVENTION 1. Field of the Invention The presentinvention is directed to the methods of producing a series ofside-by-side interconnected, sin gle-ply, multi-panel mailing envelopeforms from a continuously advancing, endless web of sheet material andto the methods of producing the stuffed, sealed envelopes resultingtherefrom. Generally, the forms comprise a pair of coplanar,envelope-defining panels separated by at least one intermediate paneldisposed between said envelope-def1ning panels and in endconnectedrelationship therewith, wherein the forms are adapted to be continuouslyfanfolded into stuffed, sealed mailing envelopes, each containing atleast one integral, interior panel. The methods of the present inventionalso provide for the selective insertion of a stuffer-insert, such as acircular or the like, in the interior of the envelope prior to scalingthereof.

2. Description of the Prior Art It is known to produce a series ofinterconnected envelope forms or assemblies from one or morecontinuously advancing, endless webs of sheet material. For example, US.Pat. Nos. 3,104,700; 3,312,385; 3,411,699; 3,544,438; and 3,608,816 eachdisclose a series of end-to-end interconnected envelope forms producedfrom a plurality of collated, continuous webs, wherein the front, backand various insert plies of each envelope are separate, independentsheets of material. US. Pat. No. 3,482,780 discloses a series ofend-to-end interconnected envelope forms produced from one web of sheetmaterial, wherein each form comprises a pair of panels defining thefront and back of a mailing envelope.

US. Pat. Nos. 3,337,120 and 3,339,827 each disclose a series ofinterconnected envelope forms produced from a plurality of collatedendless webs. It

should be noted that FIGS. 11-14 of US. Pat. No. 3,339,827 illustrate aform wherein the front and back of a mailing envelope are defined by asingle web. However, the interior sheets thereof are separate, collatedwebs.

US. Pat. No. 3,802,618 discloses a single, independent envelope formcomprising three interconnected panels, wherein the outer panels definethe front of a send and return envelope, respectively, and theintermediate panel defines the back of both the send and returnenvelope.

The present invention differs from each of the foregoing in that thedisclosed method provides for the manufacture of a series ofside-by-side interconnected, single-ply, multi-panel envelope formswhich are adapted to be presented in coplanar relationship to a printingmechanism or the like for the application of original, directly appliedindicia to the various surfaces thereof. The forms are adapted to bethereafter continuously fan-folded into stuffed, sealed mailingenvelopes.

SUMMARY OF THE INVENTION The present invention provides methods ofproducing a series of side-by-side interconnected forms from acontinuously advancing, endless web of sheet material. The web istransversely subdivided into a plurality of forms, each of whichcomprises a pair of coplanar, web-edge-adjacent envelope-defining panelsseparated by at least one end-connected, intermediate panel integral andcoplanar therewith. A pair of opposed, transversely extending side edgesare delineated in each of the panels of said forms, wherein the sideedges of each intermediate panel are disposed inwardly of thecorresponding side edges of the envelope-defining panels andinterconnected therewith.

The forms are adapted to be subsequently continuously fan-folded intostuffed, sealed envelope defining relationship wherein each envelopecontains at least one integral, intermediate panel disposedbetween thefront and back panels of the envelope.

A modification of the method provides a form compatible for use withimprint printing techniques, where such is desired. Further, the methodsof the present invention provide for the insertion of insert material,such as a circular or the like, in the interior of the enve lope priorto sealing thereof.

Therefore, it is a primary object of the present invention to provide amethod for manufacturing a series of side-by-side interconnected,single-ply, multi-panel envelope forms which are adapted to bethereafter continuously fan-folded into stuffed, sealed envelopedefiningrelationship wherein each envelope contains at least one integral,intermediate panel disposed between the front and back panels thereof.

It is, further, an object of the present invention to provide a seriesof side-by-side interconnected singleply, multi-panel envelope formswhich are adapted to be presented to a printer or the like in coplanar,interconnected relationship.

Another object of the present. invention is to provide a method forinserting insert material, such as a circular or the like, in theinterior of the envelope prior to sealing thereof.

Other objects and features of the present invention will be readilyapparent from the accompanying drawings and detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS FIGS. 1-3 diagrammatically illustratesteps in the method of making a continuous series of envelope formsincorporating the features of the present invention, wherein an oddnumber of intermediate panels are disposed between each set ofenvelope-defining panels.

FIG. 3A diagrammatically illustrates steps in a modified method ofmaking a continuous series of envelope forms incorporating the featuresof the present invention, wherein an even number of intermediate panelsare disposed between each set of envelope-defining panels.

FIGS. 4-18 illustrate an embodiment of the form produced by the methodof FIGS. 1, 2 and 3, the resulting sealed envelope obtained therefromand the means and method for opening same.

FIGS. 19 and 20 illustrate an embodiment of the form produced by themethod of FIGS. 1, 2 and 3A.

FIGS. 21-23 diagrammatically illustrate steps in the method of making acontinuous series of envelope forms similar to the forms of FIGS. 4-18,adapted for use with transfer imprint printing techniques.

FIGS. 24-27 illustrate the resulting record sheet and sealed envelopeobtained from the form produced by the method of FIGS. 21-23.

DESCRIPTION OF THE PREFERRED EMBODIMENT The methods of the presentinvention provide for the manufacture of single-ply, multi-panelenvelope forms in a side-by-side interconnected series from acontinuously advancing endless web of sheet material. The forms areadapted to be subsequently continuously fanfolded into sealed,envelope-defining relationship wherein each envelope contains at leastone intermediate panel disposed between the front and back envelopepanels. While the forms and resulting stuffed, sealed mailing envelopesare similar to the forms and envelopes of my aforementioned application,it should be understood that the methods thereof are readilydistinguishable from those disclosed herein. My copending applicationdiscloses the methods of producing a series of end-to-end interconnectedforms which are adapted to be thereafter sequentially zig-zag foldedinto stuffed, sealed mailing envelopes, whereas the present applicationis limited and directed to the methods of producing a series ofside-by-side interconnected forms which are adapted to be thereaftercontinuously fan-folded into stuffed, sealed mailing envelopes.

A first embodiment of the present invention is illustrated in FIGS.l-18, wherein each form is defined by a pair of envelope-defining panelsP and R separated by one intermediate data panel 0. The form is producedfrom the endless web of sheet material 10 which is continuously advancedthrough the steps of the method diagrammatically illustrated in FIG. 1,wherein repetitive indicia such as, by way of example, address 12,postage permit 14, box 16, and lines 18, see FIG. 4, are conventionallyprinted at station 20; stripes 22-29 of self-seal, dry or other suitableadhesive are applied at station 30; line holes 32 are punched at station34', diagonal perforated lines 36-39 and notches 48, 49 are cut by atypical crner-cut unit at station 40; transverse perforated lines 58-63are supplied at cross perforating station 50; transverse score lines 97are supplied at cross scoring station 56; and longitudinal perforatedlines 42-46 as well as longitudinal score lines 52 and 54 are suppliedat station 64.

The continuous series of forms is suitably accumulated in a conveniencepack at station 66, which it will be noted, provides a method forstoring the forms in sequential order while such are maintained as anintegral part of the advancing web. Generally, the forms aresequentially accordion folded at preselected transverse score lines 97as illustrated. It should, of course, be understood where self-seal, dryadhesive or the like is utilized, care should be taken to precludepremature contact of the various adhesive bearing areas of the form.

Broadly speaking, the web is transversely subdivided at lines 97 into aplurality of forms, each of which are subdivided by continuous scorelines 52 and 54 into three panels P, Q and R, the upper surfaces ofwhich are identified A, B, C, respectively, (FIG. 4) and the lowersurfaces of which are identified AA, BB, CC, respectively, (FIG. 5).Interconnected transverse perforation lines 36, 37, 58, 59 and 50delineate one side edge of panels P, Q and R and interconnectedtransverse perforation lines 38, 39, 61, 62 and 63 delineate the otherside edge thereof, wherein the opposite side edges 57, 62 of panel Q aredisposed inwardly of the corresponding side edges 58, 60 and 61, 63 ofpanels R and P, respectively. Trim strip 98, which comprises segments98?, 980 and 98R is defined by the space between interconnected lines38, 39, 61-63 and boundary line 97. Trim strip 99, which comprisessegments 99P, 99Q and 99R, is similarly defined by the space betweeninterconnected lines 36, 37, 58-60 and boundary line 97.

The forms accumulated at 66 are adapted tobe subsequently advancedthrough printing station 68 or the like, see FIG. 2, wherein variableindicia unique to each form such as, by way of example, invoice'block70, account number 72, name and address 74, and bar code 76 is applied.The printed forms are thereafter accumulated at station 78 in aconvenience pack similar to that at station 66.

Once printed, the forms are thereafter adapted to be advanced throughthe final processing steps as illustrated in FIG. 3, wherein the web isadvanced through fold station 89 where the forms are continuouslyfanfolded at lines 52 and 54 disposing panels P, Q and R in registeredrelationship, as particularly shown in FIG. 8. The corresponding, matedadhesive stripes 22, 25 and 26, 29 are pressed into permanent,contacting relationship at station 102, sealing the panels to oneanother as shown in FIG. 16. The resulting, continuous series ofside-by-side, sealed envelopes are then severed from the web at station104.

Trim strips 98 and 99, particularly segments 980 and 990 thereof,preclude contact between the corre sponding, mated adhesive stripes 23,27 and 24, 28 adjacent the side edges of each form, see FIG. 17.Therefore, as the forms are severed from the web at station 104, trimstrips 98, 99 are also removed and the stripes are disposed incontacting relationship as shown in FIG. 18, forming a plurality ofindependent, stuffed, sealed envelopes for distribution as shown at 106.

Where desired, stuffer-insert 88 is disposed between two adjacent panelsof the forms at station 89, wherein for example, panels Q and R aremaintained in open relationship and the stufferinsert, comprising acircular, an advertising brochure or the like, is inserted therebetween.The panels are thereafter closed at 90, housing the stuffer-insert inthe interior of the resulting envelope. Generally, the stuffer'insertwill be ofa dimension such that the peripheral edges thereof aredisposed inwardly of any adhesive stripes on the various panels on theform.

It should be noted that tractor feed mechanism 80, 80 may be utilized toproperly advance the series of forms through the final steps illustratedin FIG. 3, wherein sprocket gears or the like subsequently engage lineholes 32 and properly advance the series of forms toward fold mechanism89. This is particularly advantageous when the web is not advancedthrough the steps of FIG. 3 while under tension, but is loosely unfoldedfrom the convenience pack at station 78. In the event line holes 32 andtractor feed mechanism 80, 80 are utilized, the line holes areconveniently placed in boundary strips 96, 96 which are severed from theweb along lines 46, 46 at station 100. It should, of course, beunderstood that when the web is continuously under tension, tractor feed80, 80 and line holes 32 are not required.

It should also be noted that a number of alternate steps may beincorporated in the method of FIGS. l3 without departing from the scopeand spirit of the present invention. In particular, it should beunderstood that the sequence of events should not be considered limitingand that several of the various steps may be performed in any suitableorder. For example, it is often desirable to utilize a printingapparatus wherein the variable indicia may be applied to the moving webat high speeds, eliminating the necessity of accumulating the form at66, subsequent advancement through printer 68, and further accumulationof the forms at 78. This modification is illustrated in phantom in FIG.1, wherein jet controlled printer 108 is adapted to apply variableindicia 70, 72, 74, 75 and 76 in advance of station 66, as illustratedin FIG. 7. Essentially, jet con trolled printing combines high speedprinter 108 with computer control 101 or the like wherein computerproduced program media such as, by way of example, tape 112 providesvariable input to the printer, generating a controlled, variable indiciaoutput therefrom. When jet printing methods, as such, are utilized thecontinuous series of forms advances directly from station 64 (FIG. 1) tofold mechanism 89 (FIG. 3).

It should, of course, be understood that the self-seal dry adhesiveapplied at station 30 is but one of the many well-known adhesive meanswhich may be incorporated in the form of the present invention. Forexample, a hot-melt glue of the type having affinity for the surface ofthe web when applied, and thereafter quickly dried to a non-tacky,non-adhesive state, may be applied in lieu of stripes 22, 23, 24 and 29,eliminating the necessity of complementary stripes 26, 27, 28 and 25,respectively. Of course, pressure roll 102 would then be replaced with aheat-seal mechanism in order to effect a sealing relationship betweenabutting surfaces of the various panels. Further. a heat-seal mechanismin combination with dry-seal paper of the type wherein contactingportions of each panel are maintained in self-sealing relationship bythe applica tion of heat to selected portions thereof would altogethereliminate the need for station 30. In the event dry-seal paper isutilized, heat would be selectively applied at station 102 to effect aseal between abutting panels in areas corresponding to the variousstripes of adhesive. It should, of course, be understood that a coldglue could be used, in which event the web speed would, in someinstances, be reduced to allow a longer drying time to effect a properseal between abutting plies.

The resulting stuffed, sealed envelope, including means and methods foropening same, is illustrated in FIGS. 9l5. By incorporating diagonals36, 37 and 38, 39 with transverse lines 59 and 62,- respectively,intermediate data panel Q is of a lesser width than either of theenvelope panels P and R. Specifically, data panel Q is of a width suchthat the side edges thereof are dis posed inwardly of adhesive stripes23, 24 and 27, 28 on envelope panel P and R. As shown in FIGS. 17 and18, here greatly enlarged, the panels are fan-folded at lines 52, 54 andwhen trim strip 99, particularly segment 99Q thereof, is removed stripe23 is disposed in contacting relationship with corresponding stripe 27,forming a sealing relationship at corresponding side edges 58, 60 of theenvelope panels P and R, wherein side edge 59 of intermediate panel Q isdisposed inwardly thereof. It should, of course, be understood thatremoval of trim strip 98 similarly disposes stripes 24 and 28 inadhesive contact, wherein side edge 62 of panel Q is disposed inwardlythereof. Therefore, side edges 59 and 62 of data panel Q are disposedinwardly of and are free of connection with the sealed side edges of theenvelope.

Tear lines 42, 44 and 45 are disposed inwardly of the adhesive stripes22 and 25 along the top edge of the envelope and with correspondingnotches 48 and 49 define stub 114 for gaining access to the interior ofthe envelope, see FIG. 16. Tear line 43 on data panel Q provides meansfor separating the remaining edge of the data panel from the envelopeassembly.

As illustrated in FIGS. lll5, several alternate methods utilizing stub114 and modifications thereof are provided for gaining access to theinterior of the envelope. Preferably, the top of the envelope will begrasped as in FIG. 11 with the thumb and forefinger engaging notches 48,49 inwardly of line 44 on data panel Q. By similarly holding the bottomof the envelope and applying a quick, snap action the stub will breakloose along lines 42 and 45 and the data panel will break loose alongline 43, permitting removal thereof in one single act. It should benoted that stuffer-insert 88 will also be removed by this act if theupper edge 120 thereof is in overlapping relationship with notches 48,49. If such is not the case, the stuffer-insert may by manually removedonce the envelope has been opened.

With particular reference to FIG. 13 it can be seen that the stub mayalso be removed by tearing along lines 42, 44 and 45 without damage tothe contents of the envelope, i.e., data panel Q and, where included,

stuffer-insert 88. The data panel is then separated from the envelope atline 43 and withdrawn therefrom. It may be desirable in some instancesto provide stub 115 without notches 48, 49 (FIG. 14) wherein thepreferred means of entry is by tearing, as shown. It should, of course,be understood that the envelope can also be opened by slittingor cuttingthe assembly at line 116 (FIG. 15) as with automatic letter-openingmachinery or the like, afterwhich the data panel may be removed asdescribed in reference to FIG. 13.

FIGS. 19 and 29 illustrate a modified form produced generally by themethod of FIGS. l-3, wherein each set of envelope-defining panels P andR are separated by a plurality of intermediate panels Q, S and T.Printing station 20 is modified to provide additional repetitive indicia278 on surface B of panel Q, and repetitive indicia 280 and 292 onsurface E of panel T. Station 64 provides longitudinal perforated line250 separating panels Q and S, longitudinal score line 252 separatingpanels S and T, and score line 254 defining a foldline in the returnenvelope. Station 50 supplies additional transverse perforated lines 258and 260 connecting line 59 with diagonal 36 and transverse perforatedlines 262 and 264 connecting line 62 with diagonal 38. Station 30 ismodified to apply additional stripes of dry, selfseal adhesive 266-271,wherein stripes 266, 267 and stripes 268, 269 are disposed in contactingsealed relationship when the envelope is fan-folded at station 89 todefine an integral return envelope within the interior of the finalenvelope. The resulting stuffed, sealed mailing and return envelope issimilar to that which is fully disclosed in my aforementioned co-pendingapplication.

The method thus modified produces the form as illustrated in FIGS. 19and 20, wherein the upper surface of each of panels P, Q, R, S and T isdenoted A, B, C, D and E, and the corresponding lower surface thereof isdenoted AA, BB, CC, DD and EE respectively. The forms are subsequentlyadvanced through printing station 68, and thereafter through the finalprocessing steps of FIG. 3 wherein the various panels are continuouslyfan-folded at lines 52, 252, 250 and 54 to define a sealed mailingenvelope having at least one intermediate panel Q and an integral returnenvelope defined by panels S and T. As in the previous embodiment, trimstrips 98, 99 and boundary strips 96, 96 (where utilized) are removedand the various complementary adhesive stripes are disposed incontacting, sealed relationship with one another at stations 100, 102and 104 of FIG. 3.

FIG. 3A illustrates a modified method for producing a series ofside-by-side interconnected forms wherein an even number of intermediatepanels such as, by way of example, two panels Q and U as shown, aredisposed between each set of envelope-defining panels P and R. The stepsof FIGS. 1 and 2 are essentially the same as in the previousembodiments, afterwhich the web is continuously fan-folded at modifiedfold station 289 into envelope-defining status as illustrated at 306thereof. As in the previous embodiments, stuffer-insert 88 may bedisposed between two adjacent panels of each form prior to sealingthereof in envelopedefining relationship.

As illustrated, panels P, Q, U and R are continuously fan-folded intoregistered, overlying relationship, after which trim strips 96 areremoved at station 300, the web-edge-adjacent adhesive stripes arepermanently sealed at station 302, and trim strips 98, 99 are removed,the side edges are sealed and the individual envelopes are severed fromthe form at station 304.

Since a number of institutions presently utilize im print printingtechniques, I have provided a modified method for manufacturing a seriesof. side-by-side interconnected, single-ply, multi-panel forms which arecompatible for use with imprint printing techniques, as illustrated inFIGS. 21-23. As there shown, the method of FIG. 1 is duplicated throughstation 64 afterwhich web is advanced to modified fold station 389wherein transfer web 400 comprising carbon paper or the like, iscollated with panel Q. Collating station 390 is in partial overlappingrelationship with fold station 389, and includes sprocket chain 391 orthe like which is adapted to sequentially engage line holes 432 in web400 to ensure proper collation thereof with the continuous series offorms.

It will be noted, of course, that web 400 requires additional stripes ofadhesive 426 and 429 adjacent the line hole boundary thereof to permitproper sealing of the resulting envelope, see FIG. 27. As panels P, Qand R are continuously fan-folded into registered relationship and web400 is collated therewith, adhesive stripes 26, 426; 29,429; and 22, 25are disposed in contacting, sealed relationship in a manner similar tothat of the previous embodiments. A second transfer web of carbon paper,or the like, is collated with the folded web at station 390, whereinsprocket chain 391 sequentially engages line holes 532 thereof andregisters same with line holes 32 and 432 of webs 10 and 400,respectively. Record web 600 is similarly collated via line holes 632afterwhich the forms are accumulated in a convenience pack at station366.

It should, of course, be understood that webs 400, 500 and 600 are eachtransversely subdivided by lines 497, 597 and 697, respectively into aplurality of sideby-side interconnected panels each of which correspondto the width of one form as defined by lines 97 in panels P, Q and R.Further, trim strips 498, 499, 598, 599 and 698, 699 are provided inwebs 400, 500 and 600 to facilitate severance of the forms from theseries at station 304 of FIG. 23. The accumulated forms are subsequentlyadvanced through printing station 368, wherein indicia is directlyapplied to the upper surface of web 600 and imprint printed on panels Pand Q via transfer webs 400 and 500, afterwhich the forms are againaccumulated at station 378.

The continuous series of side-by-side interconnected forms is thereafteradvanced through the final processing steps of FIG. 23, therebygenerating the stuffed sealed envelope of FIG. 24 and the separaterecord and transfer sheets of FIG. 25. As in each of the previousembodiments, the boundary strips including the various line holes areremoved at station 301, a permanent seal is effected between contactingadhesive stripes 26, 426; 29, 429; and 22, 25 at station 302, see FIG.27, and the various trim strips 98, 99, 498, 499, 508, 599, 698 and 699are removed at station 304 where a seal is effected between the adhesivestripes 23, 27 (FIG. 26) and 24, 28 as in the previous embodiments,producing a plurality of individual, stuffed, sealed envelopes fordistribution at 306.

Where desired, stuffer-insert 88 may be inserted in the interior of theenvelope prior to final sealing thereof at station 31 l, as shown inFIG. 23. In this event, adhesive stripe 426 is not supplied on web 400prior to collation thereof with web 10, precluding sealing of panel Pthereto in advance of station 311. Panel P is lifted from the advancingseries of forms, as shown at 313, afterwhich stuffer-insert 88 isdisposed between panels P and Q at 314 and adhesive stripe 426 is addedto web 400 at station 315. Thereafter, the forms are sealed aspreviously described, housing insert 88 between panel P and web 400 asshown in FIGS. 26 and It should, of course, be understood that spotcarbon or the like could be directly applied to webs l0 and 500,eliminating the need for webs 400 and 500. Of course, the various othermodifications, such as jet printing and the like, may be incorporated inthe embodiment of FIGS. 21-27 without departing from the scope andspirit of the present invention.

Therefore, from the foregoing, it can be seen that l have provided themethods of producing a continuous series of side-by-side interconnectedforms each of which comprise the front and back panels of a mailingenvelope and at least one integral panel disposed intermediate thereof.The forms may be presented in coplanar relationship to a printer or thelike, or where desired may be adapted for use in conjunction withimprint printing techniques when carbon or the like is interposedbetween the various panels thereof. Each of the forms are adapted to befan-folded into stuffed, sealed mailing envelopes, and where desired,insert material such as a circular or the like may be inserted in theinterior of the envelope prior to sealing thereof.

What is claimed is:

1. As a new article of manufacture, a continuous series ofside-interconnected stuffed-envelope-defining forms fabricated from asingle, endless web, wherein each form comprises a series of at leastthree endintereonnected panels collectively spanning the width of theweb, wherein the web-edge-adjacent panels define the front and rearpanels of mailer envelopes and wherein the intermediate panels defineenvelope stuffers; a removable tear-strip integral with and extendingalong each side-edge of the panels of each form, said strips having aninner edge which, when severed from the form, defines the overall widthof the various panels thereof, wherein the overall width of each of theenvelope-defining panels exceeds the overall width of each of theintermediate panels; a series of sideinterconnected transfer panelsfabricated from an endless Web of transfer material, secured to, carriedby and in corresponding registry with one intermediate panel of eachform; a removable tear-strip integral with and extending along each sideedge of said transfer panels, said strips having an inner edge which,when severed from said transfer panels, defines. the overall widththereof, wherein the overall width of each transfer panel correspondswith the overall .width of the corresponding intermediate panel,adhesive along the side surfaces of the envelope-defining panels andalong the end-adjacent surfaces of those panels of the form and of thetransfer panels which are disposed in abutting contact when the panelsof the form are disposed in fan-folded relationship for disposing theenvelopedefining panels in overlying relationship and externally of theintermediate and transfer panels; said form being further characterizedin that the side edges of the intermediate and transfer panels arespaced inwardly from and free of connection with the side edges of theenvelope-defming panels.

2. An article of manufacture as called for in claim 1, which includes aninsert disposed between each transfer panel and the adjacentenvelope-defining panel.

3. An article of manufacture as called for in claim 1, wherein oneend-edge of each transfer panel is releasably connected to thecorresponding end-edge of each intermediate panel.

4. An article of manufacture as called for in claim 1, wherein a recordpanel and a second transfer panel are releasably secured to and carriedby the outer surface of an envelope-defining panel.

1. As a new article of manufacture, a continuous series ofsideinterconnected stuffed-envelope-defining forms fabricated from asingle, endless web, wherein each form comprises a series of at leastthree end-interconnected panels collectively spanning the width of theweb, wherein the web-edge-adjacent panels define the front and rearpanels of mailer envelopes and wherein the intermediate panels defineenvelope stuffers; a removable tearstrip integral with and extendingalong each side-edge of the panels of each form, said strips having aninner edge which, when severed from the form, defines the overall widthof the various panels thereof, wherein the overall width of each of theenvelope-defining panels exceeds the overall width of each of theintermediate panels; a series of side-interconnected transfer panelsfabricated from an endless web of transfer material, secured to, carriedby and in corresponding registry with one intermediate panel of eachform; a removable tear-strip integral with and extending along each sideedge of said transfer panels, said strips having an inner edge which,when severed from said transfer panels, defines the overall widththereof, wherein the overall width of each transfer panel correspondswith the overall width of the corresponding intermediate panel, adhesivealong the side surfaces of the envelope-defining panels and along theendadjacent surfaces of those panels of the form and of the transferpanels which are disposed in abutting contact when the panels of theform are disposed in fan-folded relationship for disposing theenvelope-defining panels in overlying relationship and externally of theintermediate and transfer panels; said form being further characterizedin that the side edges of the intermediate and transfer panels arespaced inwardly from and free of connection with the side edges of theenvelope-defining panels.
 2. An article of manufacture as called for inclaim 1, which includes an insert disposed between each transfer paneland the adjacent envelope-defining panel.
 3. An article of manufactureas called for in claim 1, wherein one end-edge of each transfer panel isreleasably connected to the corresponding end-edge of each intermediatepanel.
 4. An article of manufacture as called for in claim 1, wherein arecord panel and a second transfer panel are releasably secured to andcarried by the outer surface of an envelope-defining panel.